Advanced flame‐retardant epoxy resins from phosphorus‐containing diol

Phosphorus‐containing epoxy systems were prepared from isobutylbis(hydroxypropyl)phosphine oxide (IHPO) and diglycidyl ether of bisphenol A (DGEBA). Diethyl‐N,N‐bis(2‐hydroxyethyl) aminomethyl phosphonate (Fyrol 6) could not be incorporated into the epoxy backbone by a reaction with either epichlorohydrin or DGEBA because intramolecular cyclization took place. The curing behavior of the IHPO–DGEBA prepolymer with two primary amines was studied, and materials with moderate glass‐transition temperatures were obtained. V‐0 materials were obtained when the resins were tested for ignition resistance with the UL‐94 test. © 2005 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 43: 3510–3515, 2005     

Fabrication of diatomite‐based microencapsulated flame retardant and its improved fire safety of unsaturated polyester resin

To achive excellent fire resistance, new microcapsule flame retardants (DMCAD and DMPPD) were prepared using 9,10‐dihydro‐9‐oxa‐10‐phosphaphenanthrene‐10‐oxide combined with melamine cyanurate or melamine polyphosphate as the shell material and diatomite as the core material. The successful assembly of DMCAD and DMPPD was detailed characterized by Fourier transform infrared (FT‐IR) spectra, X‐ray photoelectron spectroscopy (XPS), and scanning electron microscopy (SEM). Meanwhile, the flame retardancy and thermal stability of the unsaturated polyester resin (UPR)/DMCAD and UPR/DMPPD composites were also studied. The addition of DMCAD and DMPPD effectively improves the flame retardance properties of UPR, and the effect of DMPPD was better. The limiting oxygen index (LOI) of UPR/DMPPD‐3 increased by 11.6% when compared with that of UPR, and the sample achieved V‐0 rating. Moreover, the peak heat release rate (pHRR) and the total heat release (THR) rate of UPR/DMPPD‐3 were reduced by 67% and 26%, respectively. Under nitrogen condition and air condition, UPR/DMPPD showed better thermal stability and char‐forming ability from the thermogravimetric (TG) results. Residual char of the UPR composites was systematically analyzed with SEM and XPS. Finally, the flame retardant mechanism of DMPPD was proposed.     

Preparation of phosphorylated chitosan‐coated carbon microspheres as flame retardant and its application in unsaturated polyester resin

In this work, phosphorylated chitosan‐coated carbon microspheres (PCH@CMS) was successfully synthesized. Obtained PCH@CMS used as flame retardant was added into unsaturated polyester resin (UPR). Fourier infrared spectroscopy (FTIR) and X‐ray electron spectroscopy (XPS) results indicated that C═O, P─O, and P═O appeared on the surface of PCH@CMS. Compared with UPR, the residues of UPR/PCH@CMS‐10 at 800°C under nitrogen and air atmospheres increased by 9.0 and 3.9 wt%, respectively, and the peak heat release rate (pHRR) and the peak smoke release rate (pSPR) of UPR/PCH@CMS‐3 decreased by 18.9% and 23.5%, respectively. Limiting oxygen index (LOI), thermogravimetric analyzer (TG), and cone calorimeter test (CCT) results showed that the addition of PCH@CMS could enhance the flame retardancy and smoke suppression of the UPR composites. Moreover, the residues after CCT were characterized by scanning electron microscopy (SEM), XPS, and laser Raman spectroscopy (LRS). Based on the above results, the flame retardant mechanism of PCH@CMS was proposed. The carbon layer produced by the UPR/PCH@CMS composites was tortuous and could suppress the heat and pyrolysis product exchange with UPR matrix.     

Thermally stable and flame‐retardant aromatic phosphate and cyclotriphosphazene‐containing polyurethanes: synthesis and properties

A novel flame retardant (4‐diphenylphosphoryloxyphenoxy)(4‐hydroxyphenoxy)cyclotriphosphazene (PPPZ) was prepared and characterized by FT‐IR, ³¹P‐NMR and ¹H‐NMR spectroscopy. Polyurethanes that contained aromatic phosphate groups attached to cyclotriphosphazene, with various phosphorus contents, were prepared from PPPZ, poly(propylene glycol), 1,4‐butanediol, and 2,4‐toluene diisocyanate by one‐step polymerization. The polymers prepared were characterized by FT‐IR, thermogravimetric analysis (TGA), differential scanning calorimetry (DSC) and oxygen index (LOI) measurements. The effect of the concentration of PPPZ on the thermal behavior of the polyurethane was studied. The results indicated that the glass transition temperature (T_g) of the polyurethane increased with the concentration of PPPZ. The PPPZ‐containing polyurethanes exhibited slightly higher temperatures of degradation and higher char yields than PPPZ‐free polyurethanes. Moreover, the LOI of the polyurethanes increased with increasing PPPZ content. Also studied was the possible mechanism of the flame retardancy. Copyright © 2005 John Wiley & Sons, Ltd.     

Flame‐retardant epoxy resins from o‐cresol novolac epoxy cured with a phosphorus‐containing aralkyl novolac

A novel phosphorus‐containing aralkyl novolac (Ar‐DOPO‐N) was prepared from the reaction of 9,10‐dihydro‐9‐oxa‐10‐phosphaphenanthrene‐10‐oxide (DOPO) first with terephthaldicarboxaldehyde and subsequently with phenol. The chemical structures of the synthesized compounds were characterized with Fourier transform infrared, ¹H and ³¹P NMR, and elemental analysis. Ar‐DOPO‐N blended with phenol formaldehyde novolac was used as a curing agent for o‐cresol formaldehyde novolac epoxy, resulting in cured epoxy resins with various phosphorus contents. The epoxy resins exhibited high glass‐transition temperatures (159–177 °C), good thermal stability (>320 °C), and retardation on thermal degradation rates. High char yields and high limited oxygen indices (26–32.5) were observed, indicating the resins' good flame retardance. Using a melamine‐modified phenol formaldehyde novolac to replace phenol formaldehyde novolac in the curing composition further enhanced the cured epoxy resins' glass‐transition temperatures (160–186 °C) and limited oxygen index values (28–33.5). © 2002 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 40: 2329–2339, 2002     

Synergistic effect of combined dimethyl methylphosphonate with aluminum hydroxide or ammonium polyphosphate retardant systems on the flame retardancy and thermal properties of unsaturated polyester resin

A series of flame-retardant unsaturated polyester resin (UPR) were prepared by the addition of dimethyl methylphosphonate (DMMP) with various amounts of aluminum hydroxide (ATH) or ammonium polyphosphate (APP) as the flame retardants. The combustion resistance effects of ATH/DMMP and APP/DMMP systems were evaluated by limiting oxygen index test and vertical burning test (UL-94). The thermal properties of UPR were investigated by thermogravimetric analysis. The structure of char was observed by scanning electron microscopy. DMMP incorporated with ATH or APP improved the flame retardancy and thermal properties of UPR. However, the fire-retardant mechanism of these two systems were different: The ATH/DMMP system provided synergistic effect in charring property of the UPR, produced great amount of residual char, and thus revealed the excellent flame retardancy. The APP/DMMP system further improved the flame retardancy of the UPR due to the change in the residual char structure rather than the increase in the production of char.     

A flame‐retardant phosphate and cyclotriphosphazene‐containing epoxy resin: Synthesis and properties

A novel flame‐retardant epoxy resin, (4‐diethoxyphosphoryloxyphenoxy)(4‐glycidoxyphenoxy)cyclotriphosphazene (PPCTP), was prepared by the reaction of epichlorohydrin with (4‐diethoxyphosphoryloxyphenoxy)(4‐hydroxyphenoxy)cyclotriphosphazene and was characterized by Fourier transform infrared, ³¹P NMR, and ¹H NMR analyses. The epoxy resin was further cured with diamine curing agents, 4,4′‐diaminodiphenylmethane (DDM), 4,4′‐diaminodiphenylsulfone (DDS), dicyanodiamide (DICY), and 3,4′‐oxydianiline (ODA), to obtain the corresponding epoxy polymers. The curing reactions of the PPCTP resin with the diamines were studied by differential scanning calorimetry. The reactivities of the four curing agents toward PPCTP were in the following order: DDM > ODA > DICY > DDS. In addition, the thermal properties of the cured epoxy polymers were studied by thermogravimetric analysis, and the flame retardancies were estimated by measurement of the limiting oxygen index (LOI). Compared to a corresponding Epon 828‐based epoxy polymer, the PPCTP‐based epoxy polymers showed lower weight‐loss temperatures, higher char yields, and higher LOI values, indicating that the epoxy resin prepared could be useful as a flame retardant. © 2000 John Wiley & Sons, Inc. J Polym Sci A: Polym Chem 38: 972–981, 2000     

Modified montmorillonite combined with intumescent flame retardants on the flame retardancy and thermal stability properties of unsaturated polyester resins

Modified montmorillonite‐containing phytic acid (PA‐MMT) has been prepared by acid treatment and then introduced into unsaturated polyester resin (UPR) with an intumescent flame retardant (IFRs). The flame retardancy and thermal degradation of UPR/IFRs/PA‐MMT were evaluated by a limiting oxygen index (LOI) test, a vertical burning test (UL‐94), a thermogravimetric analysis (TGA), and a cone calorimeter test (CCT). Besides, the mechanical properties were studied by a universal testing machine. The LOI value of UPR/IFRs/PA‐MMT composites was increased to 29.2%. The CCT results indicated that the incorporation of PA‐MMT and IFRs significantly improved the combustion behavior of UPR. The results of the mechanical properties indicated that 1.5 wt% loading of PA‐MMT in UPR/IFRs showed the highest improvement in flexural strength and tensile strength. The flame‐retardant mechanism of PA‐MMT/IFRs was examined and discussed based on the results of combustion behavior and char analysis.     

Synthesis of a novel DPPA‐containing benzoxazine to flame‐retard epoxy resin with maintained thermal properties

The flame‐retarded epoxy resin with improved thermal properties based on environmentally friendly flame retardants is vital for industrial application. Hereby, a novel reactive‐type halogen‐free flame retardant, 10‐(3‐(4‐hydroxy phenyl)‐3,4‐dihydro‐2H‐benzo[e] [1,3] oxazin‐4‐yl)‐5H‐phenophosphazinine 10‐oxide (DHA‐B) was synthesized via a two‐step reaction route. Its structure was characterized using ¹H, ¹³C, and ³¹P NMR and HRMS spectra. For 4,4′‐diaminodipheny ethane (DDM) and diglycidyl ether of bisphenol A (DGEBA)‐cured systems, the epoxy resin with only 2 wt% loading of DHA‐B passed V‐0 rating of UL‐94 test. Significantly, its glass transition temperature (T_g) and initial decomposition temperature (T_5%) were as high as 169.6°C and 359.6°C, respectively, which were even higher than those of the corresponding original epoxy resin. Besides, DHA‐B decreased the combustion intensity during combustion. The analysis of residues after combustion suggested that DHA‐B played an important role in the condensed phase.     

Highly efficient multielement flame retardant for multifunctional epoxy resin with satisfactory thermal,flame‐retardant,and mechanical properties

Multifunctional epoxy resins with excellent, thermal, flame‐retardant, and mechanical properties are extremely important for various applications. To solve this challenging problem, a novel highly efficient multielement flame retardant (PMSBA) is synthesized and the flame‐retardant and mechanical properties of modified epoxy resins are greatly enhanced without significantly altering their and thermal properties by applying the as‐synthesized PMSBA. The limiting oxygen index value reaches up to 29.6% and could pass the V‐0 rating in the UL‐94 test with even low P content (0.13%). Furthermore, cone calorimetry results demonstrate that 30.3% reduction in the peak heat release rate for the sample with 10.0 wt% PMSBA is achieved. X‐ray photoelectron spectroscopy and scanning electron microscopy indicate that Si‐C, Si‐N, and phosphoric acid derivative can be transformed into a multihole and intumescent char layer as an effective barrier, preserving the epoxy resin structure from fire. More importantly, mechanical properties such as impact strength, tensile strength, and flexural strength are also increased by 63.86%, 33.54%, and 15.65%, respectively, which show the incorporation of PMSBA do not deteriorate the mechanical properties of modified epoxy resins. All the results show that PMSBA is a promising strategy for epoxy resin with satisfactory, thermal, flame‐retardant, and mechanical properties.     

Preparation of phosphorus‐containing phenolic resin and its application in epoxy resin as a curing agent and flame retardant

For the sake of improving the flame retardancy of epoxy resin (EP), a novel phosphorus‐containing phenolic resin (PPR) synthesized in our group instead of conventional phenolic resin (PR) was used to cure EP in the present research. The curing processes and the corresponding crosslinking structure and mechanical performance were investigated by differential scanning calorimeter and dynamic mechanical thermal analysis. Because of the introduction of flame‐retarding elements including P and Si, PPR exhibited higher charring capacity in the condensed phase, which is helpful to construct a char layer of higher quality. Correspondingly, PPR‐cured EP displayed remarkably improved flame retardance as compared to conventional PR‐cured EP through the related evaluations including limiting oxygen index, vertical burning test, and microscale combustion colorimeter. As a multifunction agent, it is believable that PPR possesses potential commercial value to prepare flame‐retardant EP with high performance.     

A novel intumescent flame‐retardant LDPE system and its thermo‐oxidative degradation and flame‐retardant mechanisms

A carbonization agent, 3,9‐di (2‐hydroxyisopropyl)‐2,4,8,10‐tetraoxa‐3,9‐diphosphaspiro‐[5,5]‐undecane (SPEPO), was synthesized from pentaerythritol (PER), phosphorus trichloride, formic acid, and acetone as raw materials. The structure of SPEPO was characterized by FTIR and ¹H‐NMR. As a carbonization agent and an acid source, SPEPO can form a novel intumescent flame‐retardant (IFR) system for low density polyethylene (LDPE) together with ammonium polyphosphate (APP) and melamine phosphate (MP). The flame retardancy and thermal behavior of the IFR system for LDPE were investigated by limiting oxygen index (LOI), UL‐94 test, and thermogravimetric analysis (TGA). When the weight ratio of SPEPO, APP, and MP is 7:7:1 and their total loading level is 30%, the IFR‐LDPE presents the optimal flame retardancy (LOI value of 27.6 and UL‐94 V‐0 rating). However, SPEPO, APP, or MP can only show a very poor flame‐retardant performance when used alone. This indicates that there is a synergistic effect among SPEPO, APP, and MP. TGA results obtained in air demonstrate that SPEPO has an ability of char formation itself, and the char residue of SPEPO can reach 24 wt% at 700°C. The IFR can change the thermal degradation behavior of LDPE, enhance T_max of the decomposition peak of LDPE, and promote LDPE to form char based on the calculated and the experimental data of residues. According to the results of Py‐GC/MS in combination with FTIR of the char residues at different temperatures, a possible flame‐retardant mechanism has been proposed. Copyright © 2008 John Wiley & Sons, Ltd.     

Development of novel phosphorus‐containing epoxy resins from renewable resources

Novel biobased epoxy resins were prepared from two fatty acid derivatives; epoxidized 10‐undecenoyl triglyceride and epoxidized methyl 3,4,5‐tris(10‐undecenoyloxy)benzoate, with 4,4′‐diaminodiphenylmethane as a crosslinking agent. The flame retardancy of these epoxy resins was improved by the addition of 10‐[2′, 5′‐bis(9‐oxiranyl‐nonayloxy)phenyl]‐9,10‐dihydro‐9‐oxa‐10‐phosphaphenanthrene‐10‐oxide and by crosslinking with a phosphorus‐containing curing agent, bis(m‐aminophenyl)methylphosphine oxide. The thermal, thermomechanical, and flame‐retardant properties of the cured materials were measured with differential scanning calorimetry, thermogravimetric analysis, dynamic mechanical analysis, and the limiting oxygen index. © 2006 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 44: 6717–6727, 2006     

Studies on photocrosslinking and flame‐retardant properties of chalcone‐based polyacrylamides

A photocrosslinkable polycyclic chalcone‐based acrylamide has been synthesized by Claisen–Schmidt condensation reaction and then polymerized via free radical polymerization technique using azobisisobutyronitrile (AIBN) as an initiator. The resulting polymers have been characterized by FT‐IR, ¹H‐NMR and ¹³C‐NMR analytic techniques. The molecular weights of the polymers were determined by gel permeation chromatography. The thermal properties of synthesized polymers were characterized by TGA analysis, and the obtained results show good thermal and thermo‐oxidative stability which is required for a negative photo resist. The high flame‐retardant properties are calculated from limiting oxygen index (LOI) values and are found to be 36.9 and 32.0 for naphthyl and anthryl chalcone‐based polymers, respectively. The experimentally determined LOI values of polymers (PMNPA and PAPA) are 34.3 and 30.2, respectively, and the values are closer to theoretically found LOI values. However, the cone calorimetry of flame‐retardant PMNPA only showed a slight decrease in peak of heat release rate (PHRR) and total heat release (THR) compared to PAPA but the ignition time (TTI) of PMNPA is slightly higher than PAPA. The photocrosslinking properties of the polymers were investigated by UV spectroscopy technique and were found that with the increase in number of aromatic rings, the rate of crosslinking decreases. Thus polyacrylamides are useful in photolithography technology as well as flame‐retardant property in electrical appliances. Copyright © 2015 John Wiley & Sons, Ltd.     

Development of novel flame‐retardant thermosets based on benzoxazine–phenolic resins and a glycidyl phosphinate

Modified novolac resins with benzoxazine rings were prepared and copolymerized with a glycidyl phosphinate. Their curing behavior and the thermal properties of the curing resins were studied. Copolymerization was studied with model compounds considering the functionality of the benzoxazine‐based phenolic resins and the easy isomerization of the glycidyl phosphinate. Phenolic novolac resin acts as an initiator but p‐toluensulfonic acid had to be used to decrease the curing temperature and to prevent glycidyl phosphinate from isomerizing. The materials obtained exhibited high glass‐transition temperatures and retardation on thermal degradation rates. V‐0 materials were obtained when the materials were tested for ignition resistance with the UL‐94 test. © 2003 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 42: 279–289, 2004     

Synthesis and properties of flame‐retardant benzoxazines by three approaches

We propose three approaches to obtain flame‐retardant benzoxazines. In the first approach, we synthesize a novel benzoxazine (dopot‐m) from a phosphorus‐containing triphenol (dopotriol), formaldehyde, and methyl amine. Dopot‐m is copolymerized with a commercial benzoxazine [6′,6‐bis(3‐phenyl‐3,4‐dihydro‐2H‐1,3‐benzoxazineyl)methane (F‐a)] or diglycidyl ether of bisphenol A (DGEBA). The thermal properties and flame retardancy of the F‐a/dopot‐m copolymers increase with the content of dopot‐m. As for the dopot‐m/DGEBA curing system, the glass‐transition temperature of the dopot‐m/DGEBA copolymer is 252 °C, which is higher than that of poly(dopot‐m). The 5% decomposition temperature of the dopot‐m/DGEBA copolymer increases from 323 to 351 °C because of the higher crosslinking density caused by the reaction of phenolic OH and epoxy. In the second approach, we incorporate the element phosphorus into benzoxazine via the curing reaction of dopotriol and F‐a. After the curing, the thermal properties of the F‐a/dopotriol copolymers are almost the same as those of neat poly(F‐a), and this implies that we can incorporate the flame‐retardant element phosphorus into the polybenzoxazine without sacrificing any thermal properties. In the third approach, we react dopo with electron‐deficient benzoxazine to incorporate the element phosphorus. After the curing, the glass‐transition temperatures of polybenzoxazines decrease slightly with the content of dopo, mainly because of the smaller crosslinking density of the resultant polybenzoxazines. © 2006 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 44: 3454–3468, 2006     

Microwave‐assisted synthesis of a novel phosphorus‐containing spiroorthoester,characterization and cationic polymerization

A new phosphorus‐containing spiroorthoester, (1,4,6‐trioxaspiro [4,4] nonan‐2‐yl)‐methyl 3‐[10‐(9,10‐dihydro‐9‐oxa‐9‐phosphaphenanthrene‐10‐oxide)]‐propanoate (SOE‐P), was synthesized under microwave irradiation with a short reaction time (1 h), because classical thermal heating did not lead to the desired product. The structure of the new monomer was confirmed by ¹H, ¹³C, and ³¹P. SOE‐P was homopolymerized and copolymerized with phenylglycidyl ether with ytterbium triflate as a cationic initiator in DSC experiments. These reactions were monitored by FTIR/ATR, and the formation of poly(ether‐ester)s with a pendant bulky phosphorylated group was shown. © 2006Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 44: 4722–4730, 2006     

Preparation and thermal properties of a novel core‐shell structure flame‐retardant copolymer

In order to improve the flame retardancy of polystyrene (PS), a phosphorus and nitrogen comonomer, named AC₂NP₂, was synthesized and then incorporated into various amounts of PS by seeded emulsion polymerization. The modified methacrylate (AC₂NP₂) was used as the core phase, the styrene as the shell phase, then flame‐retardant effect copolymers with core‐shell structure were prepared successfully. The particle size was ranged from 40 to 60 nm, and the structure and properties of the copolymers were characterized in detail. Notably, despite a few amounts of the AC₂NP₂ units in the copolymers, all the copolymers exhibited significantly enhanced thermal stability and reduced flammability as compared with pure PS. Furthermore, from differential scanning calorimetry test, it was observed that the glass transition temperature was tinily influenced with the incorporation of commoner. The incorporation of P‐N comonomer into PS backbone did not lead to negative effect on the glass transition behavior of PS.     

Facile,one‐pot synthesis of aromatic diamine‐based phosphinated benzoxazines and their flame‐retardant thermosets

Three aromatic diamine‐based, phosphinated benzoxazines ( 7–9 ) were prepared from three typical aromatic diamines—4,4′‐diamino diphenyl methane ( 1 ), 4,4′‐diamino diphenyl sulfone ( 2 ), and 4,4′‐diamino diphenyl ether ( 3 ) by a one‐pot procedure. To clarify the reaction mechanism, a two‐pot procedure was applied, in which the reaction intermediates ( 4–6 ) were isolated for characterization. The structures of intermediates and benzoxazines were confirmed by high resolution mass, IR, and 1D and 2D‐NMR spectra. In addition to self‐polymerization, ( 7–9 ) were copolymerized with cresol novolac epoxy (CNE). After curing, the homopolymers of P( 7–9 ) are brittle while the copolymers of ( 7–9 )/CNE are tough. Dynamic mechanical analysis shows the T_gs of ( 7–9 )/CNE copolymers are 187, 190, and 171 °C, respectively. Thermal mechanical analysis shows the CTEs of ( 7–9 )/CNE copolymers are 46, 38, and 46 ppm, respectively. All the ( 7–9 )/CNE copolymers belong to an UL‐94 V‐0 grade, demonstrating good flame retardancy. © 2010 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem, 2010     

Metal‐organic framework MIL‐53 (Fe)@C/graphite carbon nitride hybrids with enhanced thermal stability,flame retardancy,and smoke suppression for unsaturated polyester resin

Metal‐organic framework MIL‐53 (Fe)@C/graphite carbon nitride hybrid (MFeCN), a novel flame retardant, was synthesized by hydrothermal reaction and subsequently added into unsaturated polyester resin (UPR). The structure, morphology, and thermal stability of MFeCN were characterized by Fourier transform infrared spectroscopy (FTIR), X‐ray diffraction (XRD), X‐ray photoelectron spectroscopy (XPS), scanning electron microscopy (SEM), transmission electron microscopy (TEM), energy‐dispersive X‐ray spectroscopy (EDS), and thermogravimetric analysis (TG). The thermal stability and flammability of the UPR composites were characterized by TG and cone calorimeter tests (CCT). The results of CCT demonstrated that the peak heat release rate (pHRR), total heat release (THR), peak smoke production rate (pSPR), and total smoke production (TSP) of UPR/MFeCN‐4 were reduced by 39.8%, 10.2%, 33.3%, and 14.5%, respectively, comparing with UPR. The results of TG and CCT indicated that MFeCN could improve the thermal stability, flame retardancy, and smoke suppression properties of the UPR composites. The residues after CCT were then characterized by laser Raman spectroscopy (LRS), XPS, and SEM. Finally, based on the above experimental results and analysis, the flame retardancy mechanism of MFeCN was proposed.